Dyna Fuel Line Replacement

M-1149 1 of 3
®
SERVICE BULLETIN
RECALL CODE 0112 - 2004 DYNA FUEL LINE REPLACEMENT
Purpose
Harley-Davidson has recently learned that a condition exists
on certain 2004 model year Dyna Glide fuel-injected motorcycles.
The rubber fuel hose has the potential to separate
from the inner liner, causing a fuel leak which could result in
a fire.
In the interest of motor vehicle safety and customer satisfaction,
Harley-Davidson has elected to initiate a voluntary recall
(Campaign 0112) to replace the affected fuel lines. See
REQUIRED DEALER ACTION to perform the recall service.
Motorcycles Affected
This recall applies to 2004 fuel-injected Dyna models
included on the attached VIN list.
Customer Notification
Harley-Davidson will send letters to registered owners notifying
them of this condition and instructing them to contact
their dealer for fuel hose replacement.
To ensure rider safety, it is your responsibility to perform the
required service on all affected vehicles even if the motorcycle
was not purchased from your dealership. You will be
required to perform the required service on all affected vehicles
in your dealership inventory prior to selling or leasing
those vehicles.
If you are not sure that a safety recall has been completed on
a particular motorcycle, check the recall records available on
TALON and h-dnet.com
IMPORTANT NOTE
Because only registered owners will receive notification
from us, we request that you contact any owners of vehicles
that your records show as unregistered. Advise
them of the safety recall and make arrangements for
them to come in for recall service. We also require that
you provide us with their names, addresses and VINs as
soon as possible to enable us to mail them an owner’s
letter, as required by the National Traffic and Motor Vehicle
Safety Act (as amended).
A shipment of Safety Recall Code 0112 kits, Part No. 94251,
will contain approximately 50% of your total estimated kit
requirements. Shipments will begin on or around February
16, 2004.
All kits will be shipped no charge, transportation paid. When
additional kits are needed, fill in the attached order form and
FAX it to the Warranty Department at 414-343-8346.

11WARNING 1WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi, 400 kPa). To
avoid an uncontrolled discharge or spray of gasoline,
always purge the system of high pressure gas before
removing the fuel supply line from the fuel tank. Gasoline
is extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious
injury.
M-1149 Safety Recall Code 0112 February 12, 2004
IMPORTANT NOTE
In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your
dealership for either maintenance or service.
Removal
1. Remove electrical caddy cover.
2. Purge the fuel supply line of high pressure gasoline.
a. See Figure 1. Disconnect the fuel pump fuse (1)
from the main wiring harness.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate the starter for three
(3) seconds to remove any remaining fuel from the
fuel lines.
11WARNING 1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove Maxi-Fuse before
proceeding. (00251a)
3. Remove Maxi-Fuse (2).
4. Remove seat. Refer to the DYNA MODELS SERVICE
MANUAL for the correct procedure.
5. Loosen, but do not remove, the acorn nut on the front
fuel tank mounting bolt.
6. Remove the rear fuel tank mounting acorn nut, bolt and
flat washers.
7. Raise rear of fuel tank approximately 2.0 in. (51 mm).
Support fuel tank in this position with a small block of
wood or other suitable device. This will provide enough
clearance to gain access to the fuel line fitting on the
induction module.
11WARNING 1WARNING
A small amount of gasoline may drain from the quickconnect
fitting when the fuel supply line is removed.
Thoroughly wipe up any spilt fuel immediately. Dispose
of rags in a suitable manner. Gasoline is extremely flammable
and highly explosive. Inadequate safety precautions
could result in death or serious injury.
8. See Figure 2. Pull up on chrome sleeve of quick-connect
fitting (1) and pull down on fuel supply line fitting (2) to
disconnect.
11WARNING 1WARNING
A small amount of gasoline will drain from the fuel supply
line when disconnected from the induction module.
Thoroughly wipe up any spilt fuel immediately. Dispose
of rags in a suitable manner. Gasoline is extremely flammable
and highly explosive. Inadequate safety precautions
could result in death or serious injury.

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Installation
1. See Figure 3. Slide
new
fuel line onto fuel supply tube
(3), until fuel line fitting (2) “clicks” in place. Gently tug on
fuel line to verify that it is locked in place.
2. See Figure 2. Pull up on chrome sleeve of quick-connect
fitting (1) on left side of tank and insert neck of fuel supply
line fitting (2). While pushing up on bottom of fuel
supply line fitting, pull down on chrome sleeve until it
“clicks” into the locked position. Tug on fuel supply line to
be sure that it will not come free.
3. Remove wood block supporting rear of fuel tank, and
lower fuel tank into position on frame backbone.
4. Install rear fuel tank mounting bolt, flat washers and
acorn nut. Tighten acorn nuts on both front and rear fuel
tank mounting bolts to 15-20 ft-lbs (20.3-27.1 Nm).
5. See Figure 1. Install fuel pump fuse (1).
6. Install Maxi-Fuse (2) and electrical caddy cover.
11WARNING 1WARNING
Do not start vehicle until fuel system has been inspected
for leaks as described in the steps below. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury.
7. Set RUN/STOP switch to RUN. Inspect fuel system for
leaks as follows:
a. Turn ignition switch ON to pressurize fuel system.
b. Inspect for leaks around fuel line fittings.
c. Wait three to five seconds and turn ignition switch
OFF.
8. Repeat previous step two to three times to ensure fuel
system is completely pressurized and verify that there
are no leaks around the fuel line fittings.
11WARNING 1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat can
shift, causing loss of control, which could result in death
or serious injury. (00070a)
9. Install seat. Refer to the DYNA MODELS SERVICE
MANUAL for the correct procedure.